Rolling-element bearing assembly

ABSTRACT

A rolling-element bearing assembly is provided herein. The rolling-element bearing assembly includes a first raceway that also includes a first sensor module and a first communication module. The rolling-element bearing assembly includes a second raceway that also includes a second sensor module and a second communication module. The first sensor module senses a different condition of the rolling-element bearing assembly than the second sensor module. The first and second communication modules are of a same type. The rolling-element bearing assembly includes a plurality of rolling elements arranged between the first and second raceways to enable the first and second raceways to be rotatable relative to each other.

CROSS-REFERENCE

This application is a Continuation Application claiming benefit to U.S.patent application Ser. No. 15/973,894 filed on May 8, 2018, whichclaims priority to German patent application no. 10 2017 208 871.0 filedon May 24, 2017, the contents of which are fully incorporated herein byreference.

TECHNOLOGICAL FIELD

The disclosure is directed to a rolling-element bearing assembly.

BACKGROUND

Some proposals for sensorized rolling-element bearing assemblies arealready known from the prior art that are configured as very specificfitting solutions.

SUMMARY

An aspect of the disclosure is to provide an improvement in thisrespect.

A rolling-element bearing assembly according to the disclosure includesthe following features:

-   -   at least one first and second rolled-on surface element, on        which rolling elements are provided for rolling,    -   at least one set of rolling elements, which is disposed between        the first and second rolled-on surface element such that the        rolled-on surface elements are rotatable with respect to each        other in the manner of a rolling-element bearing,    -   at least one first of the rolling elements comprises a first        sensor module and a first communication module to which the        first sensor module is connected,    -   at least one second of the rolling elements comprises a second        sensor module and a second communication module to which the        second sensor module is connected, and    -   the communication modules and the sensor modules are formed with        a uniform connection interface for connecting the modules.

The uniformity or standardization of the connection interfaces allowsthe use of a uniform communication module independent of theconfiguration of the sensor module, which depending on the type ofvariables to be detected must systemically be configured differently fordifferent variables. The uniformity of the communication modulesfacilitates the connection to a common receiver, and the use ofidentical subassemblies offers many advantages with respect to provisionbut also cost advantages. An adapting to the most diverse use cases isalso possible in a simple and cost-effective manner. The same appliesfor retrofitting and replacement.

Furthermore since a plurality of rolling elements are equipped withsensors, the space problem that exists if they were all to be packed ina single rolling element is solved. Furthermore variables are therebydetectable that would not be detectable this way at all using a singlesensorized rolling element. Here the rolling elements are in particulardisposed distributed in specific positions with respect to one another,for example, two disposed exactly opposite each other, or threerespectively at 120° spacing, or four respectively at 90° spacing. Ofcourse solely sensorized rolling elements can also be used.

Further advantages, features and details of the disclosure arise fromthe exemplary embodiments of the disclosure described in the followingwith the assistance of the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section through a rolling-element bearing assembly.

FIG. 2 is a longitudinal section through the rolling-element bearingassembly of FIG. 1 in the region of a rolling element including asensor.

FIG. 3 is a detail-explaining sketch of a sensorized rolling element andof a receiver.

FIG. 4 is a flow diagram of a measurement and evaluation method for arolling-element bearing assembly including sensorized rolling elements.

DETAILED DESCRIPTION

FIG. 1 shows a cross-section through a rolling-element bearing assemblyconfigured as a cylindrical roller bearing. The rolling-element bearingassembly here comprises an inner rolled-on surface element 2 configuredhollow-cylinder-shaped and an outer rolled-on surface element 4 alsoconfigured hollow-cylinder-shaped, between which a set of cylindricalrolling elements 8 and 10 is disposed such that the two rolled-onsurface elements 2 and 4 (e.g., two raceways) are rotatable or at leastpivotable against each other in the manner of a rolling-element bearing.

Here normal, conventional rolling elements 8 without sensor technologyand rolling elements 10 including sensor technology are present. Thesensor technology is disposed in the cavities of thehollow-cylindrically configured rolling element 10, or in anotherembodiment is disposed in not-axially-continuous cavities extendingoutward from the end sides of the cylindrical rolling element. Here thesensor technology comprises one or more sensors for variables such asare described in more detail, for example, with respect to FIG. 4. Herethe sensor technology of different rolling elements 10 can be configuredfor detecting the same or also different variables, for example,revolutions of rolling elements 10 and the rolling-element bearingassembly, load, and/or acoustic emissions. In some embodiments thesensorized rolling elements 10 can be distributed in specific positionswith respect to one another, for example, two disposed exactly oppositeeach other, or three respectively at 120° spacing, or four respectivelyat 90° spacing, or solely sensorized rolling elements 10 can also beused.

Furthermore in one embodiment a cage is present in which the rollingelements 8 and 10 are disposed and which prevents, for example, a mutualcontacting of the rolling elements 8 and 10. Seals can likewise beprovided that seal the rolling-element space outward so that, forexample, a lubricant, e.g., grease or oil, present in therolling-element space does not penetrate outward. The rolled-on surfaceelements 2 and 4 as well as the rolling elements 8 and 10 can bemanufactured from a rolling-element bearing steel or also any othersuitable material.

FIG. 2 shows a longitudinal section through the rolling-element bearingassembly of FIG. 1 in the region of one of the sensorized rollingelements 10. Here it can be seen that the sensor technology is disposedin the cavity of the hollow-cylindrical rolling element 10. The sensortechnology here comprises a sensor module 20 that is connected to acommunication module 40 via a connection interface 30. Here the sensortechnology of the other rolling elements 10 provided with sensors iscorrespondingly constructed, wherein with particular advantage anidentically constructed communication module is used for all sensortechnologies and the connection interface 30 is also a uniform one, withthe result that the sensor technologies differ only in their sensormodule 20 depending on the type and role of the variables to bedetected.

FIG. 3 shows a detail-explaining schematic sketch of the rolling element10 of FIG. 2 provided with sensor technology in connection with areceiver 45 disposed outside the actual rolling-element bearingassembly. Here the uniform connection interface 30 comprises fourconnecting points 32, 34, 36, and 38 and specifically one for theelectrical energy supply, a further one for analog data transmissions, afurther one for digital data transmissions, and a final one for ground.Furthermore the communication module is configured for wireless datatransfer to the receiver 45. Here the sensor module 20 can in itself beformed subdivided again from the actual sensor 22 and a correspondingamplifier 24.

By combining the measured data in particular of a plurality ofsensorized rolling elements 10 taking into account their temporalprogression and occurrence, an all-encompassing determination, forexample, of load states of the rolling-element bearing assembly isadvantageously made possible. For this purpose in one embodiment thesensorized rolling elements 10 are given a precise time stamp, which canbe realized, for example, by a time synchronization with the receiver 45via the wireless data connection.

FIG. 4 shows as one exemplary embodiment of the disclosure a flowdiagram of a method for monitoring and controlling the operation of arolling-element bearing assembly, wherein according to theabove-described configurations at least two or more of the rollingelements are equipped with a sensor for detecting noise emissions, witha load sensor, and/or with a sensor for detecting the bearing- androlling-element-rotation.

In a specification step 100 of the method the threshold values for thenoise emissions, the load, and the rolling-element slip are defined,which threshold values differ depending on the type of therolling-element bearing assembly and the application. Thereafter in afirst step 200 of the method the noise emission of the rolling-elementbearing assembly is detected by the corresponding sensor and transmittedto a receiver unit. In the receiver unit the measured and transmitteddata of the noise emission is then compared, at decision diamond 210, tothe defined threshold value for the noise emission, so that with afalling-below of the threshold value the next step 300 is continued, orin the case of the exceeding of the threshold value the step 220 iscontinued before the method continues thereafter with step 300 asrequired.

Here step 220 includes a corresponding notifying of the operator of therolling-element bearing assembly and/or the process parametersinfluencing or controlling the operation of the rolling-element bearingassembly are changed such that it can be concluded therefrom that thenoise emission has thus dropped below the defined threshold value. Insevere cases an emergency shutdown can also be initiated, whereby themethod is ended and the system would be restarted again.

In step 300 of the method the load situation of the rolling-elementbearing assembly is then detected by the corresponding sensor andtransmitted to the receiver unit. In the receiver unit the measured andtransmitted load situation is then compared, at decision diamond 310, tothe defined threshold value for the load, so that with a falling-belowof the threshold value the next step 400 is continued, or in the case ofexceeding the threshold value the step 320 is continued before themethod continues thereafter with step 400 as required. Here step 320 inturn includes a corresponding notifying of the operator of therolling-element bearing assembly that the process parameters influencingor controlling the operation of the rolling-element bearing assemblyhave changed such that it can be concluded therefrom that the load hasthus dropped below the defined threshold value. In severe cases can anemergency shutdown can also in turn be considered. In severe cases anemergency shutdown can also in turn be initiated, whereby the method isended and the system would be restarted again.

In step 400 of the method the bearing and rolling-element rotation isthen determined by the corresponding sensor for the determining of apossibly existing bearing slip and transmitted to the receiver unit. Inthe receiver unit it is then compared, at decision diamond 410, to thedefined threshold value for the slip, so that with a falling-below ofthe threshold value the next step 500 is continued, or in the case ofthe exceeding of the threshold value the step 420 is continued beforethe method continues thereafter with step 500 as required. Here step 420in turn includes a corresponding notifying of the operator of therolling-element bearing assembly that the process parameters influencingor controlling the operation of the rolling-element bearing assemblyhave changed such that it can be concluded therefrom that the slip hasthus dropped below the defined threshold value. In severe cases anemergency shutdown can also in turn be initiated, whereby the method isended and the system would be restarted again.

Finally in step 500 a general status report of the rolling-elementbearing assembly including the measured data is generated before themethod is then carried out again with step 100, etc. . . . .

The method course described above here only represents a singleexemplary embodiment. Depending on more or fewer sensors as well asdepending on sensors for detecting other variables, the flow diagramdepicted in FIG. 4 shortens or lengthens accordingly and/or handles saidother variables. Vibration in particular but also the lubricationquality or the skewing of rolling elements as well as temperature comeinto consideration as other variables. Furthermore in one embodiment atleast one accelerometer can also be provided, which can also be used,for example, to detect a change of the vibrations if the lubricatingconditions change.

Representative, non-limiting examples of the present invention weredescribed above in detail with reference to the attached drawings. Thisdetailed description is merely intended to teach a person of skill inthe art further details for practicing preferred aspects of the presentteachings and is not intended to limit the scope of the invention.Furthermore, each of the additional features and teachings disclosedabove may be utilized separately or in conjunction with other featuresand teachings to provide improved rolling element bearing assemblies.

Moreover, combinations of features and steps disclosed in the abovedetailed description may not be necessary to practice the invention inthe broadest sense, and are instead taught merely to particularlydescribe representative examples of the invention. Furthermore, variousfeatures of the above-described representative examples, as well as thevarious independent and dependent claims below, may be combined in waysthat are not specifically and explicitly enumerated in order to provideadditional useful embodiments of the present teachings.

All features disclosed in the description and/or the claims are intendedto be disclosed separately and independently from each other for thepurpose of original written disclosure, as well as for the purpose ofrestricting the claimed subject matter, independent of the compositionsof the features in the embodiments and/or the claims. In addition, allvalue ranges or indications of groups of entities are intended todisclose every possible intermediate value or intermediate entity forthe purpose of original written disclosure, as well as for the purposeof restricting the claimed subject matter.

What is claimed is:
 1. A rolling-element bearing assembly comprising: afirst raceway comprises a first sensor module and a first communicationmodule; a second raceway comprises a second sensor module and a secondcommunication module, wherein the first sensor module senses a differentcondition of the rolling-element bearing assembly than the second sensormodule, wherein the first and second communication modules are of a sametype; and a plurality of rolling elements arranged between the first andsecond raceways to enable the first and second raceways to be rotatablerelative to each other.
 2. The rolling-element bearing assembly of claim1, wherein the first sensor module comprises a first sensor interfaceoperably connected to a first communication interface of the firstcommunication module.
 3. The rolling-element bearing assembly of claim2, wherein the second sensor module comprises a second sensor interfaceoperably connected to a second communication interface of the secondcommunication module.
 4. The rolling-element bearing assembly of claim3, wherein each of the first and second sensor interfaces comprise anelectrical energy supply connecting point, an analog data transmissionconnecting point, a digital data transmission connecting point, and aground connecting point.
 5. The rolling-element bearing assembly ofclaim 1, wherein the first sensor module comprises a first sensor andthe second sensor module comprises a second sensor.
 6. Therolling-element bearing assembly of claim 5, wherein the first sensorcomprises a noise emission sensor, a load sensor, a rolling-elementrotation sensor, a temperature sensor, an acceleration sensor, or alubrication parameter sensor, and wherein the second sensor is differentfrom the first sensor.
 7. The rolling-element bearing assembly of claim1, wherein the plurality of rolling elements are disposed in a cage thatpermits communications from the first communication module to areceiver.
 8. The rolling-element bearing assembly of claim 1, whereinthe plurality of rolling elements comprise a first roller, and whereinthe first sensor module and the first communication module are disposedin a cavity that extends into an interior of the first raceway from anaxial end of the first roller.
 9. The rolling-element bearing assemblyof claim 1, wherein the first communication module or the secondcommunication module is a wireless communication module.
 10. A systemcomprising: a rolling-element bearing assembly comprising: a firstraceway comprises a first sensor module and a first communicationmodule; a second raceway comprises a second sensor module and a secondcommunication module, wherein the first sensor module senses a differentcondition of the rolling-element bearing assembly than the second sensormodule, wherein the first and second communication modules are of a sametype; and a plurality of rolling elements arranged between the first andsecond raceways to enable the first and second raceways to be rotatablerelative to each other; and a control and monitoring unit monitoring andcontrolling an operating state of the rolling-element bearing assembly,the control and monitoring unit receiving and processing outputs fromthe first sensor module transmitted by the first communication module,the control and monitoring unit receiving and processing outputs fromthe second sensor module transmitted by the second communication module,and the control and monitoring unit determining whether the output fromthe first sensor module or the output from the second sensor moduleindicates an abnormal operating condition.
 11. The system of claim 10,wherein the first sensor module comprises a first sensor interfaceoperably connected to a first communication interface of the firstcommunication module.
 12. The system of claim 11, wherein the secondsensor module comprises a second sensor interface operably connected toa second communication interface of the second communication module. 13.The system of claim 12, wherein each of the first and second sensorinterfaces comprise an electrical energy supply connecting point, ananalog data transmission connecting point, a digital data transmissionconnecting point, and a ground connecting point.
 14. The system of claim10, wherein the first sensor module comprises a first sensor and thesecond sensor module comprises a second sensor.
 15. The system of claim14, wherein the first sensor comprises a noise emission sensor, a loadsensor, a rolling-element rotation sensor, a temperature sensor, anacceleration sensor, or a lubrication parameter sensor, and wherein thesecond sensor is different from the first sensor.
 16. The system ofclaim 10, wherein the plurality of rolling elements are disposed in acage that permits communications from the first communication module toa receiver.
 17. The system of claim 10, wherein the plurality of rollingelements comprise a first roller, and wherein the first sensor moduleand the first communication module are disposed in a cavity that extendsinto an interior of the first raceway from an axial end of the firstroller.
 18. The system of claim 10, wherein the first communicationmodule or the second communication module is a wireless communicationmodule.